This article is being published to combine TSB 00-22-1 and 01-14-6 as part of a consolidated 7.3L diagnostic aid booklet.

ISSUE:

Some vehicles equipped with a 7.3L Powerstroke diesel engine with engine serial number 661894 through 1311240, may exhibit a noise above the normal sound of the diesel combustion. This noise may sound like a rod knock, but it is intermittent and increases in intensity as the engine warms up to operating temperature. This “cackle” noise may by caused by pressure variation within the fuel rail and in virtually all instances is attributed to cylinder #8 (driver side rear). The “cackle” noise does not cause damage the engine, or impact the engine’s performance or economy.

Engines after serial number 1311240 were built with a long lead injector in cylinder #8 and correct calibration from the factory. It is possible for engines with the long lead injector, from the factory or installed in service, to exhibit a “lifter noise” (the long lead injector can be identified by the “LL” stamp on top of the solenoid.) This noise is typically most noticeable when the vehicle is parked next to a brick or concrete wall, such as at a fast food drive through. This noise is a normal characteristic of the long lead injector and is not a reason to replace the injector.

ACTION:

Refer to the following Service Procedure for diagnostics, injector replacement, and Powertrain Control Module (PCM) reprogramming procedure.

SERVICE PROCEDURE

The “cackle” noise will typically be found early in an engine’s life due to low fuel pressure and/or the relationship of injectors and engine firing order, or fuel pressure below specification. If a mature engine develops the “cackle” noise, low fuel pressure is the likely cause. Before making a repair attempt, the following tests should be performed:

Verify that the noise occurs with a hot engine, not cold.

Verify that the vehicle has been driven long enough to purge the air out of the high-pressure oil system and the fuel system since the last injector/high pressure oil system repair. Air trapped in the system could induce the “cackle” noise.

If the fuel pressure is less than 379 kPa (55 psi) in either head, repair it first and re-evaluate the “cackle” concern.

Repair any other engine driveability concerns prior to attempting a repair for “cackle”. Example: low fuel pressure concerns may be causing low power and “cackle”. Repairing the low fuel pressure may correct both concerns. Also, an engine miss may be an indicator of valve train concerns.

Verify that there is no air entering the fuel system. Air entering the fuel system will affect injector timing, causing unusual noise/performance.

The Injector Performance Analyzer can be used to determine if the “cackle” is coming from cylinder #8. Cancel that cylinder to determine whether the noise still exists. “Cackle” cannot be identified using the Cylinder Contribution Test.

If the noise is only present when engine is hot, and:

no performance concern exists

fuel pressure is above the minimum specification of 379 kPa (55 psi)

there is no air present in the fuel/oil system

a long lead injector is currently not installed

then the engine is a candidate for a special Injector, F81Z-9E527-EARM (engine s/n 661894 – 896811) or XC3Z-9E527-AARM (engine s/n 896812 – end of 7.3L production).

NOTE:

IF THE NUMBER EIGHT INJECTOR HAS BEEN REPLACED PREVIOUSLY FOR A CACKLE NOISE CONCERN WITH PART NUMBER NOTED ABOVE, DO NOT REPLACE IT AGAIN. THE LONG LEAD INJECTOR CAN EXHIBIT A TICKING “LIFTER” NOISE AT NORMAL OPERATING TEMPERATURES. THIS IS CONSIDERED A NORMAL CONDITION AND DOES NOT REQUIRE SERVICE.

NOTE:

THE ENGINE SERIAL NUMBER CAN BE FOUND ON THE LOWER LEFT SIDE OF THE ENGINE BLOCK REARWARD OF THE OIL FILTER.

NOTE:

THE NEW LONG-LEAD INJECTOR FOR “CACKLE” NOISE IS USED ONLY IN CYLINDER #8. DO NOT USE IN ANY OTHER CYLINDER DUE TO FUTURE CYLINDER CONTRIBUTION TEST DIAGNOSTICS BEING AT RISK. THE INJECTOR IS RECOGNIZABLE BY AN “LL” STAMPED ON THE SOLENOID WHERE THE UVC (INJECTOR HARNESS) CONNECTS.

Replace the #8 injector by referring to the replacement procedure in the appropriate vehicle Workshop Manual. In addition to replacing the injector, the PCM MUST be reprogrammed to prevent the #8 injector from flagging a false Cylinder Contribution Test code during future diagnostic tests. After the repair, realize that some small amount of “cackle” may remain.

NOTE:

VEHICLES BUILT WITH ENGINE AFTER S/N 1311240 HAVE CORRECT CALIBRATIONS FROM THE FACTORY.

PCM CALIBRATION INFORMATION

Application

Old Part Number (-12A650-)

Old Tear Tag

New Part Number (-12A650-)

New Tear Tag

NGS/WDS Qualifier

F-250/350 M/T Federal Service Fix 1999.5

XU2F-UA

QEK0

XU2Z-UB

QEK1

WDS Release B26.4 or Later

F-250/350, F-450/550 M/T Federal Service 1999.5

XU2F-PA

ZHL0

XU2Z-PB

ZHL1

WDS Release B25.4 or Later

F-450/550/560 M/T 50S Service Fix 1999.5

XU2F-XA

VRP0

XU2Z-XB

VRP1

WDS Release B25.4 or Later

F-450/550/560 M/T 50S Service Fix 1999.5

XU2F-VA

BAW0

XU2F-VB

BAW1

WDS Release B25.4 or Later

F-250/350 M/T California Service Fix 1999.5

XU2F-YA

GLI0

XU2Z-YB

GLI1

WDS Release B25.4 or Later

F-250/350 M/T California Service Fix 1999.5

XU2F-SA

SBJ0

XU2Z-SB

SBJ1

WDS Release B25.4 or Later

F-250/350 A/T Federal Service Fix 1999.5

XU2F-ZA

YEV0, YEV1, YEV2

XU2Z-ZD

YEV3

WDS Release B25.4 or Later

F-250/350, F-450/550 A/T Federal Service 1999.5

XU2F-RA

MRT0, MRT1, MRT2

XU2Z-RD

MRT3

WDS Release B25.4 or Later

F-450/550/560 A/T 50S Service Fix 1999.5

XU2F-ABA

RXM0, RXM1, RXM2

XU2Z-ABD

RXM3

WDS Release B25.4 or Later

F-450/550/560 A/T 50S Service Fix 1999.5

XU2F-AAA

LVS0, LVS1, LVS2

XU2Z-AAD

LVS3

WDS Release B25.4 or Later

F-250/350 A/T California Service Fix 1999.5

XU2F-ACA

XWF0, XWF1, XWF2

XU2Z-ACD

XWF3

WDS Release B25.4 or Later

F-250/350 A/T California Service Fix 1999.5

XU2F-TA

HQN0, HQN1, HQN2

XU2Z-TD

HQN3

WDS Release B25.4 or Later

E-350/450 A/T Federal Service Fix 1999.5

XU2F-ADA

UYQ0

XU2Z-ADB

UYQ1

WDS Release B25.4 or Later

E-350/450 A/T California Service Fix 1999.5

XU2F-AEA

JUK0

XU2Z-AEB

JUK1

WDS Release B25.4 or Later

E-350/450 A/T California Service Fix 2000

XC2F-AND

CHK3, CHK4

XC2Z-ANF

CHK5

WDS Release B25.4 or Later

E-350 A/T California Service Fix 2000

XC2F-BBA

MYA0

XC2Z-BBB

MYA1

WDS Release B25.4 or Later

F-250/350 M/T California Service Fix 2000

XC3F-CF

ATA3

XC3Z-CG

ATA4

WDS Release B25.4 or Later

F-250/350 M/T California Service Fix 2000

XC3F-DF

FHP3

XU7Z-DA

FHP4

WDS Release B25.4 or Later

Excursion A/T 50S Service Fix 2000

YC3F-ARF

ZYS5

YU7Z-BA

ZYS6

WDS Release B25.4 or Later

Excursion A/T 50S R/C 2000

YC3F-AVA

AXD0

YU7Z-AA

AXD1

WDS Release B25.4 or Later

F-250/350 M/T Federal R/C 2000

XC3F-AF

DAC3

XC3Z-AG

XPC4

WDS Release B25.4 or Later

F-450/550 M/T California R/C 2000

XC3F-KF

VXY3

XC3Z-KG

VXY4

WDS Release B25.4 or Later

PCM CALIBRATION INFORMATION

Application

Old Part Number (-12A650-)

Old Tear Tag

New Part Number (-12A650-)

New Tear Tag

NGS/WDS Qualifier

F-250/350 A/T California R/C 2000

XC3F-EBD

NVK3, NVK4

XU7Z-AB

NVK5

WDS Release B25.4 or Later

F-250/350 A/T California R/C 2000

XC3F-PF

CNH4

XU7Z-BA

CNH5

WDS Release B25.4 or Later

F-250/350 M/T California R/C 2000

XC3F-DCA

HMR0

XC3Z-DCB

HMR1

WDS Release B25.4 or Later

F-450/550 A/T CFFV R/C 2000

YC3F-BCA

YLE0

YU7Z-CA

YLE1

WDS Release B25.4 or Later

F-250/350 A/T California R/C 2000

XC3F-DDA

UKN0

XU7F-CA

UKN1

WDS Release B25.4 or Later

E-350/450 A/T Federal R/C 2000

XC2F-APD

SZT3, SZT4

XC2Z-APF

SZT5

WDS Release B25.4 or Later

E-350/450 A/T Federal R/C 2000

XC2F-BAA

RCU0

XC2Z-BAB

RCU1

WDS Release B25.4 or Later

E-350/450 A/T California R/C 2000

XC2F-AZB

FHM1

XC2Z-AZC

FHM2

WDS Release B25.4 or Later

E-350 A/T California R/C 2000

YC2F-ATB

SBR1

YC2Z-ATC

SBR2

WDS Release B25.4 or Later

F-250/350 M/T Federal Warm Weather 1999

F81F-JE

BDT4

F81Z-JF

BDT5

WDS Release B27.8 or Later

F-250/350 M/T Federal Cold Weather 1999

F81F-AF

AWA4

F81Z-AG

AWA5

WDS Release B27.8 or Later

F-450/550/560 M/T 50S Warm Weather 1999

F81F-LE

DYK4

F81Z-LF

DYK5

WDS Release B27.8 or Later

F-450/550/560 M/T 50S Cold Weather 1999

F81F-KE

CLB4

F81Z-KF

CLB5

WDS Release B27.8 or Later

F-250/350 M/T California Warm Weath 1999

F81F-ME

ETR4

F81Z-MF

ETR5

WDS Release B27.8 or Later

F-250/350 M/T California Cold Weath 1999

F81F-CF

ZDR4

F81Z-CG

ZDR5

WDS Release B27.8 or Later

F-250/350 A/T Federal Warm Weather 1999

F81F-NG

FUT6, FUT7

F81Z-NJ

FUT8

WDS Release B27.8 or Later

F-250/350 A/T Federal Cold Weather 1999

F81F-BH

XLE6, XLE7

F81Z-BK

XLE8

WDS Release B27.8 or Later

F-450/550/560 A/T 50S Warm Weather 1999

F81F-RG

HPA6, HPA7

F81Z-RJ

HPA8

WDS Release B27.8 or Later

E350/E450 A/T Federal 1998-1999

F8UF-AFG

MLU6

F8UZ-AFH

MLU7

WDS Release B27.8 or Later

E350/E450 A/T California 1998-1999

F8UF-AGG

PTH6

F8UZ-AGH

PTH7

WDS Release B27.8 or Later

Obtain an Authorized Modifications Decal (FPS 8262 – obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.

AUTHORIZED MODIFICATIONS

THE FOLLOWING MODIFICATIONS HAVE BEEN MADE:

Replaced or Reprogrammed Powertrain Control Module (PCM) per TSB 03-21-39.

THESE MODIFICATIONS HAVE BEEN APPROVED, AS APPROPRIATE, BY EPA AND CARB.

DEALER NUMBER:——————————————DATE:

CHANGE AUTHORITY:

FPS 8262 9/78 FORD MOTOR COMPANY PRINTED IN U.S.A.

PART NUMBER

PART NAME

F81Z-9E527-EARM

#8 injector (s/n 661894 – 896811)

XC3Z-9E527-AARM

#8 Injector (s/n 896812 – end of 7.3L production)

OTHER APPLICABLE ARTICLES:

NONE

SUPERSEDES:

00-22-1, 01-14-6

WARRANTY STATUS:

Information Only

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle.